1961 E Type roadster (875136) Total restoration for a client in Germany

Specification (briefly) for this project is as follows: Total restoration of early outside latch E Type with some subtle performance and reliability upgrades.

After stripping the shipping primer from the new boot floor assembly, the new panel is then sealed with etching primer....

Your engine rebuild has now been completed.

Repairing your damaged oil pan drain plug...

The following sequence of photographs shows the cylinder hone in progress, as well as the balancing of your crankshaft...

Honing cylinders to size
Balancing crankshaft

Sibylle, best wishes for a speedy recovery from everyone at Classic Jaguar! We'll take care of your car, you take care of yourself 

Connecting rods have been resized, rebushed and balanced	Crankshaft dampner is in poor condition and will be replaced	Surfacing your cylinder head

We have now media blasted your car and sealed the body (and all other bare metal panels) in epoxy primer. 875136 is now waiting in line for the full treatment in the CJ Coachworks.

Bare metal sealed with epoxy primer
Door frames are really nasty	Bonnet belly pan is very rusty

Lots of progress in the CJ engine machine shop. Your cylinder head was corroded around the water jackets on the deck surface. We ground away the corroded aluminum and built up a bead of weld that will allow us to re-cut the jackets back to their original ship. Once the deck surface is surfaced, these repairs will be virtually invisible. We have also been buy with the block, cutting the freeze plug holes ready to accept upgraded cupped plugs. The last photo below shows a set of our brand new Team CJ forged pistons...

	'
Water jackets are corroded and will be repaired		Pressure testing head - OK
Crank gear (far right) had to be cut off and will be replaced	Grinding away corrosion around water jackets	After heating in oven, head was welded  around edges of water jackets
Block on mill having core plug holes machined
Team CJ forged pistons will be used in this rebuild

Darrell has been busy cutting away all the corroded sheet metal and your car has already been despatched for blasting. In the mean time, the guys in the machine shop have been tearing down your engine. Lots of progress this week!

Floor cross member was rusty
	Floor not straight
	Inner sill poorly patched	Trans tunnel patched
Boot compartment has all sorts of  problems and shoddy repairs	Rust beneath IRS radius arm mounting cups
More patches inside boot compartment
Cutting away outer sill	Inner sill rusty
	Inside cowl side panels is also rusty
Boot floor has a whole series of patches		Early style reverse lamp housing riveted to boot floor
Cutting away boot floor assembly
Early style support rails will be kept for reference purposes		Doors will be skinned min two pieces to work with narrow early chrome
Engine tear down underway	Head has corroded water jackets
	Disassembling cyl head	Screw welded to crank - not the way to balance a crankshaft!
Timing tensioner rubber pad was  hanging by a thread	No lock tabs used by previous rebuilder	Broken off bolt left in block
Freeze plugs will be upgraded to later cup style		Crack testing the block (OK)
Boring out old sleeves	First of sleeves removed

We now have your car completely disassembled and ready for media blasting.

Interior was soaking wet from being  left oustide in elements		IRS has many early features
Early hollow steering column is dented and weakened - will be replaced	Engine bay now completely stripped	Body placed on blasting rotisserie

I am pleased to report that your car has arrived safely in Austin and we already have the restoration underway. I hope you enjoy following the progress on the website over the coming months!

Car originally had outside latches	Boot floor has a number of early features
Welded louvers	Early screen chrome	Correct early door top chrome
Never seen a door skin removed like this - complete with door handle!	Driver's door is badly damaged